Stepped Cutting Insert Rising Surface for Chip Flow Stability
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Solution Overview
Problem
Existing cutting inserts for machining workpieces face challenges in efficiently managing chip contact and discharge, particularly in semi-rough machining, where the contact area between the chip and the peripheral surface is limited, leading to instability and potential damage to the cutting edge.
Innovation Solution
The cutting insert features a unique design with a rising surface that includes a first recessed portion, a first protruding portion, a second protruding portion, and a first stepped portion, which reduce the contact surface area between the chip and the rising surface, stabilizing chip behavior and reducing the risk of cutting edge damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a recessed portion is formed in the rising surface to reduce chip contact area, then chip discharge performance is improved, but the stability of chip behavior deteriorates
Solution Approach 1:
The rising surface is segmented into multiple functional zones: a first recessed portion for initial chip reception, a first protruding portion with a first front end portion for chip guidance, a second protruding portion for additional chip control, and a first stepped portion connecting them. This segmentation allows different regions to perform specific functions - the recessed portions reduce overall contact area for better discharge, while the protruding portions provide stable guidance points for chip behavior control.
Solution Approach 2:
Different regions of the rising surface are given different geometric properties: the first recessed portion provides a cavity for chip accommodation, the first protruding portion creates a localized barrier at the first front end portion, the second protruding portion adds another control point, and the first stepped portion creates a height transition zone. Each local region has optimized quality characteristics that collectively solve both the discharge performance and stability requirements.
2Object-affected harmful factors
If the contact surface area between chip and rising surface is reduced, then cutting edge damage risk is reduced, but chip control capability deteriorates
Solution Approach 1:
The rising surface structure is divided into discrete elements (first recessed portion, first protruding portion, second protruding portion, first stepped portion) that collectively reduce the continuous contact area between chip and surface, thereby reducing cutting edge damage risk from prolonged contact, while each segment maintains specific geometric features for chip control.
Solution Approach 2:
The first protruding portion and second protruding portion act as intermediary elements between the chip and the rising surface. These protruding portions create localized contact points that mediate chip behavior - providing guidance and control without requiring large contact areas, thus reducing damage risk while maintaining control capability.
Data Source
AI summary
A cutting insert includes an upper surface and a lower surface. The upper surface includes a first corner, a first side, a rake face, and a rising surface. The rising surface includes a first recessed portion recessed with respect to the first side, a first protruding portion located farther from the first corner than the first recessed portion, a second protruding portion located between the first protruding portion and the first side, and a first stepped portion located between the first protruding portion and the second protruding portion. The first protruding portion has a first front end portion located closest to the first side. A cross section orthogonal to the first side and including the first front end portion is a first cross section. At the first cross section, the second protruding portion is located closer to the lower surface than the first protruding portion.